Tufting machine

ABSTRACT

A tufting machine includes a feed roller assembly formed of a plurality of coaxially aligned and detachable shaft members.

CROSS REFERENCE TO RELATED APPLICATION

[0001] This patent application is a continuation of U.S. applicationSer. No. 10/190,777 filed Jul. 5, 2002, “Tufting Machine.”

BACKGROUND OF THE INVENTION

[0002] 1. Field of the Invention

[0003] The present invention is directed to a tufting machine, and moreparticularly, an improved feed roller assembly for a tufting machine.

[0004] 2. Description of the Related Art

[0005] Tufting machines are widely used for manufacturing tufted pilefabrics, such as carpeting. Many tufting machines include yarn feedroller pattern attachments or assemblies configured to producevariations in pile height of the carpet products.

[0006] yarn feed roller assemblies typically include groups of yarn feedrollers which are driven at different speeds. The rollers in each groupare arranged parallel to each other and are closely spaced. An array ofstrands of yarn are guided across each group of rollers.

[0007] Pattern attachments known as “full repeat scrolls” include anarray of yarn wheels rotatably mounted adjacent to each roller. One yarnwheel is provided for each strand of yarn guided across each roller. Theyarn wheels are movable in and out of engagement with the yarn. In theengaged position, the yarn wheel presses the yarn against the roller.Thus, because the yarn roller is driven, the yarn roller pulls the yarninto the tufting machine.

[0008] The yarn wheels can be independently driven. Additionally, theyarn rollers can be driven at different speeds. Thus, by driving theyarn wheels into and out of engagement with different rollers, adjacentstrands of yarns can be fed at different rates. Additionally, the feedrate of a single strand of yarn can be changed quickly. Differentfeeding rates result in different pile heights in the resulting carpetproduct.

[0009] Examples of such machines are sold under the trademark Cobble™.These machines can be configured to provide two or three different pileheights in a carpet. Additionally, these machines can be configured toproduce rolls of carpet approximately 13 feet wide. In such machines,the yarn rollers are made from metal shafts approximately four meterslong.

[0010] In order to prevent bending and vibration of the feed rollersduring operation, the scroll attachments are divided into a number ofparallel yarn feeding bays. In one example, the bays are approximately24 inches wide and are separated by bearing supports. Thus, each shaftis supported by 8 bearing supports. The bearing supports includerecesses for receiving roller bearings which are mounted to each shaftin an known manner.

[0011] The shafts are made out of a strong metal material such as steel.The outer surface of the rollers, however, is covered with a softermaterial which provides a desired friction against the strands of yarnso as to transfer the rotational movement of the shaft to a lineardisplacement of the yarn strands. One type of covering that is commonlyused is known as “Northrop Type LHP.”

[0012] As a result of prolonged operation, the outer covering of therollers can become worn or damaged. For example, the covering can bedamaged to the point where the covering loses the ability to providetraction against the yarn. Thus, the yarn disposed in contact with thatportion of the covering will not be fed properly. The resulting carpetproduct will have a visible flaw.

[0013] In order to allow the covering to be replaced, the covering canbe procured in a roll having a narrow width, such as, for example, 2inches wide. After the original covering has been removed, replacementcovering can be re-applied by rotating the feed roller and wrapping thecovering in a helical pattern around the outer surface of the roller.

[0014] This manner of replacing the outer surface of the roller allowsthe roller to remain installed on the tufting machine without having toremove the numerous strands of yarn from the machine. However, thisprocess of resurfacing the feed rollers produces a length of carpetproduct that is unacceptable for resale. Thus, the roll of carpet beingproduced at that time must be cut so as to remove the unacceptableportion. Further, the roll of carpet being manufactured will not be of astandard length and thus would be resold as a remnant, or “odd size” andthus is usually sold for less than full price.

[0015] Another common repair performed on tufting machines, and inparticular, full repeat scroll attachments, is related to the yarnwheels. As noted above, the yarn wheels are driven into and out ofengagement with the feed rollers. Occasionally, a bearing whichrotatably journals the yarn wheel fails. This failure results in animproper feeding speed of a particular strand of yarn. When a yarn wheelbearing fails, the feed rollers have to be dislodged so that the yarnwheels can be removed. In certain full repeat scroll attachments, thebearing support assemblies for the feed rollers are hingedly mounted toa frame. Thus, the feed rollers can be dislodged by removing two boltsfrom each bearing support assembly so that the bearing supportassemblies can be pivoted about their respective hinges. For a machinewith seven bays, 16 bolts have to be removed before the feed rollers canbe pivoted, i.e., two bolts for each bearing support assembly.

[0016] Another common component to fail on tufting machines is the feedroller bearings. Known feed rollers are formed from a single steel shafthaving a number of bearings press fit thereon. Additionally, as notedabove, the portions of the shaft between the bearings are covered with asoft outer covering to provide friction against the yarn. Thus, when oneof the bearings fails, the entire shaft must be removed, as well as theouter covering of the shaft, so that the damaged bearing can be removed.If the damaged bearing is near the center of the shaft, adjacentbearings also must be removed so that the damaged bearing can beremoved.

SUMMARY OF THE INVENTION

[0017] One aspect of the present invention includes the realization thatcertain repairs to known full repeat scroll attachments can be made morequickly if portions of the feed roller can be removed or dislodgedindependently without the need to remove or dislodge the entire feedroller.

[0018] Another aspect of the present invention includes the realizationthat several of the drawbacks the of prior art spiral-wound yarn rollercoverings can be overcome by using a vulcanized covering. For example,when the prior art helical covering is applied to a yarn roller, thecovering should be applied so that adjacent edges of the windings are asclose as possible. However, when this type of covering is applied duringmaintenance of a used tufting machine, the covering is applied by hand,while the shaft is in place with two arrays of yarn strands extending infront of and behind the shaft. Thus, at least slight imperfections inthe spacing of the windings of the covering are inevitable. A vulcanizedcovering, however, provides substantially seamless outer surface, andthus, does not suffer from the problems caused by the presence of ahelical seam on the outer surface of the roller.

[0019] In accordance with yet another aspect of the present invention, atufting machine comprises a frame assembly, and a plurality of parallelyarn feeding bays supported by the frame. An inlet yarn guide issupported by the frame and is configured to guide a plurality of yarnstrands into each of the bays. A needle assembly is supported by theframe and is configured to reciprocate relative to the frame. An outletyarn guide is configured to guide the yarn strands from the bays intothe needle assembly. The tufting machine also includes first and secondfeed roller assemblies, each extending across all of the bays. At leastfirst and second bearing assemblies support both of the first and secondfeed roller assemblies. Each of the first and second bearing assembliesare disposed between two of the bays. First and second drives areconfigured to drive the first and second feed roller assemblies,respectively, such that the first feed roller assembly is driven at aspeed greater than a speed of the second feed roller assembly. First andsecond wheels mounted adjacent the first and second feed rollerassemblies, respectively, and are moveable between first and secondconfigurations. In the first configuration, the first wheel presses afirst yarn strand against the first feed roller. In the secondconfiguration, the second wheel presses the first yarn strand againstthe second feed roller. Each roller assembly comprises at least firstand second coaxially aligned cylindrical members, each having a terminalend disposed in the vicinity of one of the bearing assemblies which aredisposed between two bays.

[0020] In accordance with a further aspect of the present invention, atufting machine comprises at least two parallel yarn feeding bays. Atleast one bearing support assembly is disposed between the bays. Atleast one feed roller assembly extends across the bays. A plurality ofwheels are moveable into and out of engagement with the feed rollerassembly. The feed roller assembly comprises a plurality of co-axiallyaligned rollers being separable at a position in the vicinity of thebearing support assembly.

[0021] In accordance with yet another aspect of the present invention, atufting machine comprises at least first, second, and third parallelyarn feeding bays. The second bay is between the first and second bays.At least one roller assembly extends across all three bays. At least onewheel is moveable into and out of engagement with the roller assembly.The feed roller assembly comprising first, second, and third feedrollers aligned with the first, second, and third bays, respectively.Additionally, the machine includes means for allowing the second rollerto be removed without removing the first and third rollers.

[0022] In accordance with another aspect of the present invention, atufting machine comprises a plurality of parallel yarn feeding bays. Atleast one roller assembly extends across all three bays, the feed rollerassembly comprises a vulcanized outer covering.

BRIEF DESCRIPTION OF THE DRAWINGS

[0023] These and other features, aspects, and advantages of the presentinvention will now be described with reference to the drawings ofpreferred embodiments which are intended to illustrate and not to limitthe invention. The drawings comprise the following figures:

[0024]FIG. 1 is a partial sectional and side elevational view of a knowntufting machine with a full repeat scroll attachment having two pairs ofyarn feed rollers and corresponding sets of yarn wheel pitman arms;

[0025]FIG. 2 is an enlarged perspective view of one of the pitman armsshown in FIG. 1;

[0026]FIG. 3 is an enlarged elevational view of the pitman armillustrated in FIG. 2 pivoted in the first position such that the loweryarn wheel presses a strand of yarn against the lower yarn feed roller;

[0027]FIG. 4 is an elevational view of the pitman arm and rollerassembly shown in FIG. 3 with the pitman arm pivoted in a secondposition with the upper yarn wheel pressed against the upper yarn feedroller;

[0028]FIG. 5 is perspective view of a tufting machine including a feedroller and bearing support assembly construction in accordance with thepresent invention;

[0029]FIG. 6 is an elevational view of one of the roller shaftsillustrated in FIG. 5;

[0030]FIG. 7 is an enlarged perspective view of a portion of a bearingsupport assembly illustrated in FIG. 5, the right side portion of theillustrated bearing support assembly, as vied in the figure, having twocap members removed;

[0031]FIG. 8 is a top plan view of the terminal ends of two of theshafts illustrated in FIG. 6 having bearings near their terminal endsand having a key extending between the terminal ends of the shafts, thebearings and the terminal ends of the shaft being received and recessesformed in the bearing support illustrated in FIG. 6.

[0032]FIG. 9 is a bottom plan view of one of the cap members illustratedin FIG. 7; and

[0033]FIG. 10 is a side elevational view of the cap member illustratedin FIG. 9;

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

[0034] With reference to FIGS. 1-4 an overall configuration of a knowntufting machine 10 is described to assist the readers understanding of apreferred environment of use of the present invention. The tuftingmachine 10 is described in reference to a coordinate system wherein alongitudinal dimension of the machine 10 extends in a directiongenerally horizontally and transversely to the direction through whichyarn is fed through the machine 10. In addition, relative heights areexpressed as elevations in reference to the undersurface of the machine10.

[0035] Generally, the machine 10 includes a frame assembly 12, a needlehead assembly 14, a yarn inlet 16, a yarn feed assembly 18, and a yarnoutlet assembly 20. In the illustrated machine 10, the inlet 16, yarnfeed assembly 18, and the outlet 20 define a scroll attachment of thetufting machine 10. The head 14, inlet 16, feed assembly 18, and theoutlet 20 are supported by the frame 12.

[0036] The frame 12 includes a number of load bearing members, brackets,and legs for supporting the head 14, inlet 16, feed roller assembly 18,and outlet 20.

[0037] The inlet 16, feed assembly 18, and outlet 20 are configured toguide a plurality of yarn strands from the yarn supply (not shown) tothe lower end of the needle head 14. The yarn strands Y1, Y2,illustrated in FIG. 1, each represent an array of yarn strands fed fromthe yarn supply. The arrays of yarn strands Y1, Y2 are interlaced so asto alternate along the longitudinal length of the machine 10, as knownin the art.

[0038] The inlet 16 includes a tensioner 22 and a strand guide 24. Thetensioner 22 includes a pair of guide rods 26, 28 that can be rotatedrelative to each other to adjust the tension in the yarn strands Y1, Y2.The yarn guide 24 separates the yarn strands Y1 from the yarn strandsY2.

[0039] The feed assembly 18 includes a first drive roller assembly 30and a second drive roller assembly 32. The first drive roller assembly30 is configured to control the feeding of yarn strand Y2. The secondfeed roller assembly 32 is configured to control the feeding of yarnstrand Y1.

[0040] The outlet 20 includes a nip roller assembly 34 and a jerker 36.The construction and operation of the nip roller 34 and the jerker 36are known in the art and are not described further.

[0041] The needle head 14 includes the plurality of spaced push rods 38which are reciprocally mounted within the head 14. A needle bar 40 ismounted at the lower ends of the push rod 38.

[0042] The needle bar 14 supports at least one row of needles. In theillustrated embodiment, the needle bar supports two rows of needles 42,44. The needles 42, 44 reciprocate, up and down, along with the pushrods and needle bar 40. The yarn strands Y1, Y2 are arranged in themachine 10 such that the upper feed roller assembly 30 controls the feedof yarn strand Y1 to the needles 42 and the lower feed roller assembly32 controls the feed rate of the yarn strands Y2 to the needle 44. Theneedles 42, 44 cooperate in a conventional manner with loopers and hooks(not shown) mounted beneath the head in a manner well known in the art.

[0043] Each of the roller assemblies 30, 32 include a pair of feedrollers. In particular, the upper feed roller assembly 30 includes anupper roller 46 and a lower roller 48. The lower feed roller assembly 32includes an upper roller 50 and a lower roller 52. All of the rollers46, 48, 50, 52 are made from single shafts which extend along thelongitudinal length of the machine 10.

[0044] Each of the roller assemblies 30, 32 include a plurality ofbearing support assemblies 54, 56. In one known machine 10, the shafts46, 48, 50, 52 are approximately four meters long. The bearing supports54, 56 are spaced along the longitudinal length of the shafts, 46, 48,50, 52. In a machine in which the shafts 46, 48, 50, 52 are four meterslong, eight bearing support assemblies 54 are arranged along thelongitudinal length of the shafts 46,48. The same number of bearingsupport assemblies 56 support the shafts 50, 52.

[0045] The bearing support assemblies 54, 56 are spaced approximately 24inches apart. Thus, the bearing support assemblies 54, 56 define sevenyarn feeding bays along the longitudinal length of the shafts 46, 48,50, 52.

[0046] The machine 10 also includes a feed roller drive system fordriving the rollers 46, 48, 50, 52. In one known machine, the rollers46, 50 are driven at a speed lower the speed at which the rollers 48, 52are driven. As such, each of the feed roller assemblies 30, 32 can feeda yarn strand at either the lower speed corresponding to the rotationalspeed of the shafts 46, 50, or at the higher speed corresponding to therotational speed of the shafts 48, 52.

[0047] In order to engage a yarn strand with either the low speed orhigh speed roller, each of the feed roller assemblies 30, 32 include aplurality of control arms 58, 60, respectively. Since each arm and itsassociated feed rollers are substantially identical and operate in thesame manner, only one such arm, i.e., the control arm 60 is described ingreater detail below, with reference to FIGS. 2-4.

[0048] With reference to FIG. 2, each control arm 58, 60 comprises asubstantially flat rectangular plate 62. Preferably, the plate isconstructed from a metal such as aluminum, however other metals orplastic can be used. Each control arm 58, 60 also includes a pair ofyarn wheels 64, 66. The yarn wheels 64, 66 are rotatably mounted toshafts 68, 70, respectively. The shafts 68, 70 are mounted to the plate62. Preferably, the yarn wheels 64, 66 include bearings 72, 74,respectfully, which journal the wheels 64, 66 for rotation relative tothe shafts 68, 70.

[0049] With reference to FIG. 2, each of the wheels 64, 66 are mountedsuch that a periphery of the wheels 645, 66 project beyond an elongatededge 76 of the plate 62. The projection of the wheels 64, 66 allowsthese wheels to engage the rollers 46, 48, 50, 52, described in greaterdetail below. Adjacent to each wheel 64, 66 and slightly upstream in thedirection of travel of a yarn strand, guide plates 80 are mounted alongthe edge 76 of the plate 62.

[0050] Each guide member generally has a rectangular configuration.However, at the edge adjacent to the wheels 64, 66, each guide member 80has a concave portion 82. The contour of the concave portions 82 arecomplimentary to the outer surface of the feed rollers 46, 48, 50, 52.

[0051] The guides 80 are mounted such that a clearance space is providedbetween the feed rollers 46, 48, 50, 52 and the portions 82. A guideslot 84 is formed in each of the guide members 80. During operation, ayarn strand Y1, Y2 passes through the guide slot 84 so that the yarnstrand remains aligned with the yarn wheels 64, 66. Fingers 86, 88 areformed at the upper and lower ends of the plate 62, respectively. Pins90, 92 are mounted to the fingers 86, 88, respectively.

[0052] A journal member 94 is disposed at approximately the center ofthe plate 62. The journal member 94 preferably is formed from a bearingmaterial such as brass for forming a pivot journal for the arm 58, 60.The journal member 94 defines a female member having a substantiallyc-shaped configuration. The limbs of the c-shaped configuration definevertically spaced apart surfaces 96, 98. Additionally, a concave surface100 is formed between the surfaces 96, 98.

[0053] The arms 58, 60 also include an abutment member 102. The abutmentmember 102 is spaced from the journal member 94, such that a pivotingforce can be applied to the plate 62, described in greater detail below.On alternate arms 58, 60 across the machine 10, the abutment members 102are adjacent to and slightly below the yarn wheel 66. On the other arms,the members 102 are adjacent to and above the yarn wheel 64. Preferably,the abutment members 102 are attached to the arms 50, 60 by a rivet 104.With reference to the upper portion of FIG. 2, a hole 106 is providedfor receiving the rivet 104. With reference to FIG. 1, pivot rails 108,110 are mounted to the frame 12 and extend longitudinally along the feedroller assemblies 30, 32, respectively.

[0054] With reference to FIGS. 3 and 4, an enlarged elevational view ofthe feed roller assembly 32 is provided. However, it is to be noted thatthe feed roller assembly 30 is constructed and operates in substantiallythe identical manner as the feed roller assembly 32. Thus, furtherdetail on operation of the feed roller assembly 30 will not be provided.100521 As shown in FIGS. 3 and 4, the rail 110 includes a fulcrum member112 which extends into the journal member 94. Advantageously, thefulcrum member 112 includes a convex terminal end 114 which has a shapecomplimentary to the concave portion 100 of the journal member 94.Additionally, the upper and lower surfaces 96, 98 are spaced at adistance greater than the thickness of the fulcrum member 94. Thus, asthe arm 60 pivots about the convex end 114 of the fulcrum member 112,the spacing of the upper and lower surfaces 96, 98 is sufficiently largethat the upper and lower surfaces 96, 98 do not contact the outersurfaces of the fulcrum member 112.

[0055] Springs 116, 118 are attached to the upper and lower pins 90, 92of the arm 60. One end of each spring 116, 118 is attached to the pins90, 92, respectively. The other ends of the springs 116, 118 are mountedrelative to the frame assembly 12.

[0056] At least one actuator 120 is supported by the frame 12 in thevicinity of the abutment portion 102. The actuator 120 can be in theform of any type of actuator, including for example, but withoutlimitation, pneumatic actuators, solenoid driven actuators, hydraulicactuators, piezoelectric actuators, and stepper motors. In theillustrated embodiment, the actuator 120 is a pneumatic actuator havinga plunger 122 contacting the abutment portion 102. Another pneumaticcylinder 124 is mounted such that its plunger contacts the abutmentportion of an arm adjacent to the arm 60.

[0057] The pneumatic cylinders 120, 124 are controlled in a known mannerso as to pivot the arm 60. For example, when the pneumatic cylinder 120is filled with air such the plunger 122 is extended, as shown in FIG. 3,the yarn wheel 66 presses the yarn strand Y1 against the roller 52, andthus the yarn wheel “engages” the outer covering. The arm strand isthereby pulled from the yarn supply at a speed corresponding to therotational speed of the feed roller 52. Advantageously, the spring 118is stronger than the spring 116. Thus, when the air is released from thepneumatic cylinder 120, the arm 60 pivots to the position shown in FIG.4 such that the yarn wheel 64 presses the yarn strand Y1 against thefeed roller 50.

[0058] In reference to FIG. 1, the machine 10 also includes a controller130. The controller 130 can be in the form of any known controller whichwould be appropriate for controlling a large number of actuators. Forexample, a programmable logic controller (PLC) can be used. In theillustrated embodiment, where pneumatic cylinders 120, 124 are used asthe actuators, the controller 130 also includes a high pressure airsupply 132. The high pressure air supply 132 is connected to each of thepneumatic cylinders 120, 124 so that the cylinders, 120, 124 can beindependently actuated. Thus, when a signal to provide a greater amountof yarn to the needle associated with the arm 60 is transmitted to thecontroller 130 from a pattern control (not shown) the controller 130 cantrigger the air supply 132 to provide air to the pneumatic cylinder 120and thereby press the yarn strand Y1 against the high speed roller 52.Thus, the yarn strand Y1 will feed at a higher speed to the needleassembly and thereby provide a higher pile. This type of yarn feedingapparatus is known as a “full repeat scroll” because the feeding rate ofeach yarn strand can be independently controlled.

[0059] The controller 130 can be of any conventional type, such as, forexample, but without limitation, a hard-wired system, a dedicatedprocessor and memory storing one or a plurality of control routines, ora general purpose processor and memory storing one or a plurality ofcontrol routines, or other devices.

[0060] After prolonged operation, the arms 58, 60 can become damaged.For example, the bearings 72, 74 can become damaged. When the bearings72, 74 become damaged, the corresponding yarn wheel 64, 66 can becomeseized. Once one of the wheels 64, 66 are seized, yarn will not feedproperly. Thus, the arms 58, 60 occasionally have to be replaced.

[0061] In order to replace the arms 58, 60, the rollers 46, 48 or therollers 50, 52 must be moved so that the arms 58 or 60 can be accessed.Thus, the bearing supporting assemblies 54, 56 are hingedly supportedrelative to the frame 12. In particular brackets 140, 142 are hingedlyengaged with a portion of the frame 12. Thus, the brackets 140, 142hingedly support the bearing support assemblies 54, 56, respectively.Each of the bearing support assemblies 54, 56 are attached to the frameassembly with two other bolts (not shown). Thus, when it is desired toreplace one of the arms 58 from the feed roller assembly 30, two boltsmust be removed from each bearing support assembly 54 therein. In amachine having rollers 46, 48 with a length of four meters, divided intoseven yarn bays, 16 bolts must be removed to allow the bearing supportassemblies 54 to pivot relative to the frame 12. With the bearingsupport assembly 54 pivoted as such, a repairman can reach behind therollers 46, 48, to remove and replace the arm 58.

[0062] Another repair that must be performed regularly is thereplacement of the outer surface of the rollers 46, 48, 50, 52. Forexample, after prolonged use, the yarn strands Y1, Y2 can cut grooves inthe soft outer covering of the rollers 46, 48, 50, 52. When the coveringis damaged as such, the covering must be removed and then replaced.

[0063] The feed rollers of a full repeat scroll attachment areparticularly vulnerable to this type of failure because these systemsrely on wheel pressure against the roller to provide the necessaryfriction for pulling the yarn strands. In other tufting machineattachments which use only a single roller to feed a particular strandof yarn, the roller are provided with a larger diameter than that of thefeed rollers 46, 48, and the strands of yarn are wrapped around asubstantial portion of the roller to provide a large contact patchbetween the yarn and the roller. Thus, yarn wheels generally are notused to press the yarn into engagement with such feed rollers.

[0064] However, in full repeat scroll attachments, such as in thetufting machine 10, the yarn strands are guided along a path that issubstantially tangential to the feed rollers. The yarn wheel presses theyarn strand against the roller, thereby generating a small contactpatch. Thus, significant pressure is necessary to generate sufficientfriction between the yarn strand and the roller. The pressure applied bythe yarn wheel causes the outer covering of the feed rollers to bedamaged quickly. For example, in one known machine, the outer coveringof the feed rollers lasts only about two weeks of operation. After thecovering is damaged, it must be replaced.

[0065] One known method for replacing the covering is to rotate theshafts 46, 48, 50, 52 and wind a new covering on in a helical fashion.This procedure causes, in one machine, a three-foot section of carpet tobe produced with incorrect pile heights. Thus, this portion of carpetmust be discarded. Furthermore, the roll of carpet being manufactured atthis time will have an odd size and thus must be sold as a second.

[0066] Another component that must be replaced occasionally is thebearings supporting the rollers 46, 48, 50, 52. These bearings (notshown) supported by the bearing support assemblies 54, 56 are difficultto replace because the rollers 46, 48, 50, 52 are long and are of auniform outer diameter. Thus, if a bearing in the middle of the shafthas failed, several bearings will have to be removed along with theouter covering, before the damaged bearing can be removed.

[0067] With reference to FIGS. 5-10, an improved bearing support andfeed roller assembly is illustrated therein. The bearing support andfeed roller assembly illustrated in these figures can be provided on themachine 10 illustrated in FIGS. 1-4. However, the assembly could also beprovided on other tufting machines or other scroll attachments, havingdifferent configurations, different numbers of feed rollers, and havingdifferent types of supports for the yarn wheels. However, as anillustrative, but non-limiting example, the improved bearing support andfeed roller assemblies are described below as being used with a machine10′ which can be the same as the machine 10 illustrated in FIGS. 1-4,except as noted below. Thus, in FIGS. 5-10, similar components will beidentified with the same reference numerals, except that a “′” has beenadded thereto.

[0068] With reference to FIG. 5, the machine 10′ includes upper andlower feed roller assemblies 30′, 32′.

[0069] Although the machine 10′ includes seven yarn bays, only five areillustrated and are identified by the reference numerals 160, 162, 164,166, 168. The feed roller assemblies 30′, 32′ each include two feedroller assemblies 46′, 48′ and 50′, 52′, respectively.

[0070] Each of the feed roller assemblies 46′, 48′, 50′, 52′ comprise aplurality of coaxiallly aligned cylindrical members. In the illustratedembodiment, each of the cylindrical members comprises a feed rollershaft 170. Additionally, each feed roller assembly 46′, 48′, 50′, 52′,are supported by eight bearing support assemblies. Thus, the upper feedroller assembly 30′ includes eight bearing support assemblies 172. Thelower feed roller assembly 32′ includes eight bearing support assemblies174. In the illustrated embodiment, the bearing support assemblies 172,174 can be identical.

[0071] Advantageously, each of the shafts 170 include terminal ends inthe vicinity of the bearing support assemblies 172, 174. Thus, in theillustrated embodiment, each shaft 170 is substantially only as long aseach bay 160, 162, 164, 166, 168.

[0072] The feed roller assemblies 30′, 32′ also include driveshafts 176which extend beyond the last yarn bay 168. The driveshafts 176 areconnected to feed roller drives (not shown) which drive the rollerassemblies 46′, 50′ at one speed, and drive the other roller assemblies48′, 52′ at a different speed. Alternatively, the driveshafts 176 forthe feed roller assemblies 48′, 52′, could extend from the other end ofthe machine 10′.

[0073] With reference to FIG. 6, each feed roller shaft 170 includes acentral elongate cylinder member 178. The terminal ends 180, 182 of thecentral member 178 have a reduced diameter relative to the centralportion of the member 178. Each terminal end 180, 182 includes a slot184, 186, respectively. Adjacent to each of the terminal ends 180, 182,a roller bearing 188, 190 is press fit onto the central member 178. Thereduced diameter of the terminal ends 180, 182 makes it easier to fitthe lower bearings 188, 190 over the terminal ends 180, 182.

[0074] The portion of the central member 178 between the roller bearings188, 190 includes an outer covering 192, which is configured to providetraction with the yarn strands Y1, Y2. Preferably, the outer covering192 is made from a vulcanized polymer. A presently preferred covering192 is polyurethane that is vulcanized to the central member 178. Such apolyurethane is available in a variety of widths, or can be suit to adesired width. Preferably, the polyurethane is wound around the centralmember 178 in a plurality of layers and then heated to vulcanize thelayers together and to the central member 178. After vulcanization, thevulcanized polyurethane is preferably ground to provide a more uniformouter surface. As such, the covering 192 can be provided with a surfacethat is smoother than that of the prior art, helically-wound, outercoverings.

[0075] With reference to FIG. 7, the bearing support assemblies 172, 174each include a base member 194 and four cap members 196, only two of thecap members 196 being shown in FIG. 7. The base member 194 includes tworecessed portions 198, 200. The shape of the recessed portions 198, 200are substantially identical. Thus, only the recessed portion 198 isdescribed in detail below.

[0076] The recessed portion 198 includes three semi-circular concavesurfaces 202, 204, 206. The concave surfaces 202, 206 are sized toreceive the outer surfaces of the bearings disposed on terminal ends ofa shaft 170, e.g., bearings 190 or 188. The concave surface 204 is sizedto be more than twice as long as the terminal end 180, 182 of the shaft170 having a reduced diameter.

[0077] The base member 194 also includes at least one mounting hole 208for mounting the base member 194 to the frame 12′ of the machine 10′.However, the base member 194 could have any number of mounting holes.Preferably, the base member 194 includes at least three mounting holes208. Additionally, the base member 194 includes at least eight mountingholes 210 for securing the cap members 196 thereto, described in greaterdetail below.

[0078] With reference to FIG. 8, the base members 194 can receive theterminal ends of two shafts 170. For example, as shown in FIG. 8, theconcave surfaces 206 and 202 can receive the roller bearings 188, 190 oftwo adjacent shafts 170. As noted above, the concave surface 204 ispreferably twice as wide as the terminal ends 182, 180 of adjacentshafts 170. Thus, with the bearings 188, 190 received in the surfaces202, 206, the terminal ends 180, 182 can both be received in the concavesurface 204 with a small clearance remaining between the terminal ends180, 182.

[0079] Advantageously, a key 214 is received within the slots 184, 186when the bearings 188, 190 are received in the concave surfaces 202,206. Thus, rotational energy can be transferred between the shafts 170through the key 214.

[0080] Preferably, the key 214 is sized so as to form an interferencefit with both of the slots 184, 186. The key 214 can be made from anysuitable material. A presently preferred key 214 is made from a phenoliccomposite material. Constructing the key 214 from a phenolic provides anadditional advantage in that phenolic materials can be configured to beslightly more elastic than metal. Thus, a tighter interference fit canbe achieved where the key is made from a phenolic rather than metal. Forpurposes of illustration, a center line 216 of the base member 194passes through the gap between the terminal ends 180, 182 and throughthe key 214, in the plan view illustrated in FIG. 8.

[0081] With reference to FIGS. 9 and 10, the caps 196 are configured tocooperate with the base member so as to enclose the bearings 188, 190and the terminal ends 180, 182. Thus, the cap members 196 each include arecessed portion 220 that is configured to overlap with half of therecess 198. In particular, the cap 196 includes two concave surfaces222, 224. The concave surface 224 is substantially identical to aconcave surface 202 of the base member 194 in terms of its diameter.Although the concave surface 222 has the same diameter as the concavesurface 204, the surface 222 is only half as wide as the surface 204.Thus, using two cap members such as the cap member 196 and a second capmember that is a mirror image (relative to the center line 216) of thecap member 196 the two shaft ends received in the base member 194illustrated in FIG. 8 can be covered and thus securely journaled forrotation.

[0082] With reference to FIG. 7, advantageously, the recessed surfaces202, 204, 206 are recessed from an upper surface 230 of the base 194. Asshown in FIG. 7, the concave surfaces 202, 204, 206 are recessedinwardly from the upper surface 230 by a distance identified by thereference numeral 232. This recess forms side walls to 234, 236.

[0083] With reference to FIG. 10, the recessed portion 220 in the capmember 196 preferably is formed, at least partially, in a projection 238of a lower surface 240 of the cap member. The projection 238 definesside walls 242, 244. Thus, when the cap member 196 is installed to thebase 194, the projection 238 is received within the recess defined byside walls 234, 236. This cooperation provides for easier installationof the cap members 196 and insures proper alignment therewith. The capmembers 196 also preferably include bolt holes 246 which are configuredto align with holes 210 in the base member 194.

[0084] With reference to FIG. 5, if a pivot arm 58′ in bay 168 fails,the shafts 170 corresponding to the portions of the feed rollerassemblies 46′, 48′ in bay 168 can be removed without removing the othershafts 170 which form the remaining portions of the feed rollerassemblies 46′, 48′. For example, in order to remove the shaft 170 inbay 168 of feed roller assembly 46′, the cap members 196 identified bythe letters A and B can be removed by removing the four bolts which holdthese cap members to the base members 194. Once the cap members A and Bare removed, the shaft 170 can be pulled outwardly and removed frommachine 10′. With a single piece of the feed roller assembly 46′removed, the damaged arm 58 can be removed and replaced. Additionally,if the outer covering of the shaft 170 is damaged, the shaft 170 can beremoved and replaced without having to drive or “jog” the machine 10′.Thus, there is no need to cut the carpet currently being produced by themachine 10′ and thus an odd size roll is not produced. Finally, if oneof the bearings on the shaft 170 were damaged, they could be removed andreplaced without having to remove the entire feed roller assembly 46′.

1. A tufting machine comprising a frame assembly, a plurality ofparallel yarn feeding bays supported by the frame, an inlet yarn guidesupported by the frame and configured to guide a plurality of yarnstrands into each of the bays, a needle assembly supported by the frameand configured to reciprocate relative to the frame, an outlet yarnguide configured to guide the yarn strands from the bays into the needleassembly, first and second feed roller assemblies, each extending acrossall of the bays, at least first and second bearing assemblies supportingboth of the first and second feed roller assemblies, each of the firstand second bearing assemblies being disposed between two of the bays,first and second drives configured to drive the first and second feedroller assemblies, respectively, such that the first feed rollerassembly is driven at a speed greater than a speed of the second feedroller assembly, at least first and second wheels mounted adjacent thefirst and second shafts, respectively, the first and second wheels beingmoveable between first and second configurations in which the firstwheel presses a first yarn strand against the first feed roller in thefirst configuration, and in which the second wheel presses the firstyarn strand against the second feed roller when the rocker arm is in thesecond configuration, wherein each roller assembly comprises at leastfirst and second coaxially aligned cylindrical members, each having aterminal end disposed in the vicinity of one of the bearing assemblieswhich are disposed between two bays.
 2. The tufting machine according toclaim 1, wherein each cylindrical member includes a slotted end.
 3. Thetufting machine according to claim 2, additionally comprising a key,wherein at least two of the cylindrical members are arranged such thattheir respective slots are adjacent each other, the key extending intoboth slots.
 4. The tufting machine according to claim 3, wherein the keyis constructed of a phelonic material.
 5. The tufting machine accordingto claim 4, wherein the key is sized so as to provide an interferencefit with the slots.
 6. The tufting machine according to claim 1, whereinthe cylindrical members include a vulcanized coating.
 7. The tuftingmachine according to claim 1, wherein the bearing assemblies arecomprised of a base member having first, second, and third recesses, thesecond recess being disposed between the first and third recesses. 8.The tufting machine according to claim 7, wherein the first and secondrecesses are configured to support first and second bearings,respectively, the first and second bearing being disposed on the firstand second cylindrical members, respectively.
 9. The tufting machineaccording to claim 8, wherein the first and second recesses are spacedsuch that the terminal ends of the first and second cylindrical membersare spaced from each other when the first and second bearings aredisposed in the first and second recesses, respectively.
 10. The tuftingmachine according to claim 9, wherein each of the terminal ends includeslots.
 11. The tufting machine according to claim 10 additionallycomprising a key sized so as to extend into both of the slots.
 12. Thetufting machine according to claim 11, wherein the second cylindricalmember is rotated by the first cylindrical member, all of the torquetransferred from the first cylindrical member to the second cylindricalmember passing through the key.
 13. The tufting machine according toclaim 11, wherein the third recess is sized to receive the portions ofthe terminal ends including the slots and the key.
 14. The tuftingmachine according to claim 9, wherein the bearing assemblies furthercomprise at least first and second cap members, the first cap memberbeing configured to overlie the first recess and at least a portion ofthe second recess, the second cap member being configured to overlie thethird recess and at least a portion of the second recess.
 15. Thetufting machine according to claim 14, wherein the first and second capmembers are sized such that when the first cap member is placed tooverlie the first bearing received in the first recess, the secondbearing be placed into and removed from the second recess withoutremoval of the first cap member.
 16. A tufting machine comprising atleast two parallel yarn feeding bays, at least one bearing supportassembly disposed between the bays, at least one feed roller assemblyextending across the bays, a plurality of wheels each being moveableinto and out of engagement with the feed roller assembly, the feedroller assembly comprising a plurality of co-axially aligned rollersbeing separable at a position in the vicinity of the bearing supportassembly.
 17. The tufting machine according to claim 16, wherein eachroller includes a slotted end.
 18. The tufting machine according toclaim 17 additionally comprising a key, wherein at least two of therollers are arranged such that their respective slots are adjacent eachother, the key extending into both slots.
 19. The tufting machineaccording to claim 18, wherein the key is constructed of a phenolicmaterial.
 20. The tufting machine according to claim 18, wherein the keyis sized so as to provide an interference fit with the slots.
 21. Thetufting machine according to claim 16, wherein the rollers include avulcanized coating.
 22. The tufting machine according to claim 16,wherein the bearing support assemblies are comprised of a base memberhaving first, second, and third recesses, the second recess beingdisposed between the first and third recesses.
 23. The tufting machineaccording to claim 22, wherein the first and second recesses areconfigured to support first and second bearings, respectively, the firstand second bearing being disposed on first and second of the pluralityof rollers, respectively.
 24. The tufting machine according to claim 23,wherein the first and second recesses are spaced such that terminal endsof the first and second rollers are spaced from each other when thefirst and second bearings are disposed in the first and second recesses,respectively.
 25. The tufting machine according to claim 24, whereineach end of each roller includes a slot.
 26. The tufting machineaccording to claim 25 additionally comprising a key sized so as toextend into two of the slots.
 27. The tufting machine according to claim26, wherein the first roller rotates the second roller, wherein all ofthe torque transferred therebetween passes through the key.
 28. Thetufting machine according to claim 27, wherein the third recess is sizedto receive the portions of the terminal ends including the slots and thekey.
 29. The tufting machine according to claim 23, wherein the bearingassemblies further comprise at least first and second cap members, thefirst cap member being configured to overlie the first recess and atleast a portion of the second recess, the second cap member beingconfigured to overlie the third recess and at least a portion of thesecond recess.
 30. The tufting machine according to claim 29, the firstand second cap members are sized such that when the first cap member isplaced to overlie the first bearing received in the first recess, thesecond bearing be placed into and removed from the second recess withoutremoval of the first cap member.
 31. A tufting machine comprising atleast first, second, and third parallel yarn feeding bays, the secondbay being between the first and second bays, at least one rollerassembly extending across all three bays, at least one wheel moveableinto and out of engagement with the roller assembly, the feed rollerassembly comprising first, second, and third feed rollers aligned withthe first, second, and third bays, respectively, means for allowing thesecond roller to be removed without removing the first and thirdrollers.
 32. A tufting machine comprising a plurality of parallel yarnfeeding bays, at least one roller assembly extending across all threebays, the feed roller assembly comprising a vulcanized outer covering.33. The tufting machine according to claim 32 additionally comprising anarray of yarn wheels moveable into and out of engagement with the outercovering.
 34. The tufting machine according to claim 32, furthercomprising a key made from a phenolic material.
 35. A method ofreplacing material covering a feed roller of a tufting machine,comprising: removing a feed roller having an outer covering from atufting machine; removing the outer covering from the feed roller; andapplying a vulcanized covering on the feed roller.
 36. The method ofclaim 35, wherein the vulcanized covering is applied by winding apolymer around the feed roller in a plurality of layers.
 37. The methodof claim 36, wherein the vulcanized covering is applied by heating thepolymer to vulcanize the plurality of layers together onto the feedroller.
 38. The method of claim 35, wherein the vulcanized covering ispolyurethane.
 39. A feed roller adapted for use in a tufting machine,the feed roller is driven by the tufting machine to control the feedingspeed of strands of yarn and comprising a feed roller having a contactpatch adapted to engage a plurality of strands of yarn, wherein thecontact patch comprises a vulcanized material.
 40. The feed roller ofclaim 39, wherein the vulcanized material is polyurethane.
 41. The feedroller of claim 39, wherein the contact patch is generally smooth.
 42. Amethod of covering a feed roller of a tufting machine comprising a feedroller having a contact region configured to engage a plurality ofstrands of yarn, the method comprising applying a polymer covering tothe contact patch of the feed roller, vulcanizing the polymer covering.43. The method of claim 42, wherein the polymer covering is applied bywinding a plurality of layers around the feed roller.
 44. The method ofclaim 43, wherein the polymer covering comprises polyurethane and theplurality of layers of polyurethane are vulcanized to the feed roller.45. The method of claim 42, further comprising removing the feed rollerfrom a tufting machine and removing an outer covering from the contactpatch of feed roller before applying the polymer covering to the contactpatch of the feed roller.
 46. The method of claim 42, further comprisinggrinding the vulcanized polymer covering to provide a more uniform outersurface of the feed roller.
 47. A method of applying a covering to afeed roller of a tufting machine, the feed roller driven by an actuatorof the tufting machine so as to control feeding of a plurality ofstrands of yarn, the method comprising: applying a first material to anouter surface of the feed roller; and heating the first material on thefeed roller.
 48. The method of claim 47, wherein heating comprisesmelting the material.
 49. The method of claim 47, wherein heatingcomprises vulcanizing the first material.
 50. The method of claim 47,wherein applying a first material comprises applying a plurality oflayers of the first material to the outer surface of the feed roller.51. The method of claim 50, wherein heating comprises melting theplurality of layers.